technical section of tender documents for cooling
TRANSCRIPT
1
TECHNICAL SECTION
OF
TENDER DOCUMENTS
FOR
COOLING WATER TREATMENT PACKAGE
AT
NATIONAL FERTILIZERS LIMITED
BATHINDA
Dec. 2016
2
INDEX
(Technical Section)
SECTION – A
1.0 INTRODUCTION 2.0 DETAILS OF EXISTING COOLING WATER SYSTEM
2.1 Cooling Towers
2.2 Filtration System
2.3 Blow down
2.4 Chlorination and Acid dozing system
2.5 CW Heat Exchangers and Operating Temperature
2.6 Make up water characteristics
2.7 Present cooling water treatment programme
SECTION - B
3.0 TECHNICAL REQUIREMENTS OF PROPOSED COOLING WATER
TREATMENT PROGRAMME
3.1 General requirements of cooling water treatment package
3.2 Cooling Water Treatment Scheme
3.3 Contingency treatment
3.4 Alternative chemicals for water treatment
3.5 Mobilization and stabilization
3.6 Monitoring
3.7 Essentials / Performance Guarantees
3.8 Penalties and termination
SECTION - C
4.0 INSTRUCTIONS TO BIDDERS
4.1 Technical quote
4.2 Bid evaluation
4.3 Guaranteed overall annual cost
4.4 Vendor’s Scope
4.5 Owner’s Scope
4.6 Trial order
4.7 Contents of offer
4.8 Splitting of the Contract
4.9 Availability of chemicals without interruption
ANNEXURES
I Make up water analysis for last one year
II a, IIb & IIc Heat Exchangers' - data 3
3
TECHNICAL SECTION
SECTION – A
TECHNICAL SPECIFICATIONS OF EXISTING COOLING WATER SYSTEM AND
TREATMENT PROGRAMME
TENDER DOCUMENT FOR COOLING WATER TREATMENT PROGRAMME
1.0 Introduction
NFL BATHINDA Fertilizer complex consists of Natural Gas based Ammonia Plant (900 MTPD) &
Urea plant (1550 MTPD), Captive Power Plant integrated with Steam Generation Plant, Ammonia
Storage facilities, Water Treatment Plants, Cooling Water system, Effluent Treatment plant, Bagging
Plant etc.
Plant has been commissioned in November/ December' 1978 and has been modified with Ammonia
Fuel Changeover Project and commissioned in January 2013.
2.0 DETAILS OF THE COOLING WATER SYSTEM
2.1 Cooling Towers: -
Ammonia CT Urea CT CPP CT
MAKE Paharpur Cooling Towers
Model 664-3-08 bolts SS/CS
Himalaya Pine / fir
Treated Pine / fir
Concrete
TYPE
FRAMEWORK
FILLING
BASIN
NO. OF CELLS 10 4 3
TEMP. IN / OUT ºC. (Max) 44/34 44/36 42/35
COOLING WATER CIRCULATION
(NORMAL) M³/Hr 16500 8000 to
10000
8000
DRIFT LOSS M³/Hr @ 0.1 % of Circulation
water 17 10 8
EVAPORATION LOSS M³/Hr 300 148 101.6
BLOW DOWN RATE APPROX. M³/Hr 40.0 30.0 15.0
SYSTEM VOLUME (APPROXIMATE) M3 6000 3000 1800
2.2 Filtration: -
Ammonia Urea CPP
NO. OF FILTERS 3 2 3
TYPE OF FILTER PRESSURE SAND
FILTERS
(HORIZONTAL)
PRESSURE SAND
FILTERS
(HORIZONTAL)
PRESSURE SAND
FILTERS
(VERTICAL)
EXTENT OF
FILTRATION (M³/Hr.)
400 200 240
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2.3 Blow down:
Blow down for Ammonia, Urea and CPP Cooling Towers combined is within 100M3/hr,
including intermittent blow down from cooling tower cells and sand filters.
2.4 Chlorination and Acid dozing System:
Following dosing systems are available for all the cooling water systems:
(a) Sulphuric acid dosing is done for maintaining pH of the circulation water system of CT-1,
CT-2 & CPP cooling towers, if required.
(b) Chlorine is being dozed through vacuum type chlorinators for maintaining desired level of
free residual chlorine in return water.
(c) Chemicals are at present being dozed through electronic metering pumps supplied by the
party.
2.5 Cooling Water Heat Exchangers and Operating Temperatures: -
2.5.1 Ammonia Plant:
Shell and tube heat exchangers with cooling water, mainly, on tube side are in operation. The
material of construction is generally stainless steel (SS-304) type. Synthesis Gas water cooler
AEA-603, AGB-601 E-1, E2 & E3 are having cooling water on shell side. It may be noted that
maximum temperature on process side is about 175 ºC and cooling water outlet is 45 ºC.
2.5.2 Urea Plant:
The material of construction of heat exchangers is generally stainless steel. In CO2 booster
compressor intercoolers, the cooling water is on shell side for 1st stage intercooler & in others, it
is on the tube side. In CO2 main compressor UGB-102 intercooler it is on shell side. It may be
noted that the maximum temperature on process side of the coolers is as high as 200 ºC.
The operating data of various important heat exchangers in Ammonia, Urea Plants and CPP on
the process and waterside is listed in Annexure-II a, b & c respectively.
2.6 Make-up Water Characteristics:
2.6.1 The makeup water to all the three Cooling Towers is filtered water coming from Raw Water
filtration Plant after clari-flocculation and filtration through gravity sand filters.
The makeup filtered water analysis is generally in following range:
Parameters Unit Range
Total Hardness as CaCO3 ppm 93~109
Calcium Hardness as CaCO3 ppm 60~79
Magnesium Hardness as CaCO3 ppm 30
Silica as SiO2 ppm 1.80~2.60
Chloride as CaCO3 ppm 5.6~6.0
M-alkalinity as CaCO3 ppm 51 ~62
Sulphates as CaCO3 ppm 40 ~55
Iron ppm 0.08
PH - 7.8
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2.7 Present Cooling Water Treatment Programme (Circulating Water Parameters):
Parameters Unit Ammonia Urea CPP
Total hardness as CaCO3 ppm 514~818 380~604 637~840
Calcium Hardness as CaCO3 ppm 366~580 250~415 462~577
Magnesium Hardness as CaCO3 ppm 148~238 130~190 175~263
Chloride ppm 123~254 123~225 123~254
PH - 6.9~8.0 6.9~8.2 7.0~8.2
Turbidity NTU 5~16 6~11 9~18
Total Inorganic Phosphate ppm 9~14 9~16 9~14
Zinc ppm 0.3~1.0 0.3~1.0 0.3~1.0
Iron as Fe ppm <1.0 <1.0 <1.0
Total Ammonia ppm 0~60 11~250 0 - 20
2.7.1 The following chemicals are being used in the present Cooling Water Treatment
Programme in all the three cooling towers:
Name/Trade No. Function
Descophos 50 C 2089 Scale cum Corrosion inhibitor
Descophos 50 C 209 Dispersant / Anti-precipitant
Descophos 50 C 208 Cathodic corrosion inhibitor (Zinc booster)
FLOCEP 5305 BD Bio-dispersant NVM
FLOCEP CLO ClO2 Precursor
BIOCIDE AK 5301 Oxidizing biocide (Bromine based)
BIOCIDE AK 5306 Non-oxidizing biocide (Carbamate)
BIOCIDE AK 5307 Non-oxidizing biocide (MBT)
BIOCIDE AK 5308 Non-oxidizing biocide (QUAT)
BIOCIDE AK 5310 Non oxidizing biocide (Isothiozoline)
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SECTION – B
3.0 Technical Requirements for Proposed Cooling Water Treatment Programme
3.1 General Requirements for Cooling Water Treatment package a) NFL requires vendors to provide Non-Chromate, Ortho-Phosphate- Zinc, based cooling water
treatment package for the Ammonia, Urea & CPP cooling towers of Natural Gas based
Ammonia Plant at Bathinda plant. The cooling water treatment shall comprise of Zinc as the
cathodic inhibitor and stabilized ortho-phosphate as the anodic inhibitor combined as a single
formulation. Individual chemicals as cathodic and anodic inhibitors in basic chemical form
are not acceptable. The products offered should be field tested and proven.
b) A dedicated scale inhibitor- cum-dispersant shall also be included in the programme for
dispersion of iron, general scale, and sludge and to take care of chances of scaling due to
operation at high pH. Treatment should ensure no scaling in the heat exchangers. There
should not be reduction in heat transfer capacity of heat exchangers, due to fouling or
formation of deposits.
c) Effective control of biological growth shall be provided by using suitable biocide, bio-
dispersant together with chlorine dioxide or NaBr. Vendor should quote for 3 or more non-
oxidizing biocides. Doses should correspond to MIC of the particular biocide.
d) It is desirable to have continuous dozing of Corrosion inhibitor & scale dispersant preferably
by metering pumps for good control. For solid dosing of chemical the vendor should mention
the method of dosing.
e) Blow down should be suitable for discharge into the inland surface water drains which should
be within the IS: 2490 (1981) and MINAS specifications. Chemicals and treatment
programme should meet this requirement without exception. The total quantity of blow down
from all cooling towers needs to be maintained below the present level as given at 2.3 with
the indicative make up water analysis specified at 2.6.1. The SRB limits in make-up water
shall be 5 Nos. per 100 ml (normal) and 20 Nos. per 100 ml (max.). Vendors should mention
the water blow-down after each non-oxidizing biocide dosage along with dispersant dosage at
percent (%) of system volume and quantity. Excess blow down or make up if resorted to
without valid reasons, NFL reserves the right to recover the cost of excess water consumed
along with cost of chemicals from the party.
f) Treatment programme should be capable of sustained operation under the prevailing
conditions and should be able to tolerate, ingress of ammonia, urea dust and oil, occasional
ingress of coal dust, fly ash, etc., which may also take place in the cooling towers. Details of
contingency limits are indicated at 3.3.
g) Changeover of cooling water treatment shall be on line i.e. without plant interruption. On line
changeover chemicals, if required, shall be indicated separately but form a part of the
contract.
h) Chemicals shall be supplied in new HDPE containers. The containers must be properly sealed
and also shall be labeled properly with name, brand name, batch no, expiry date etc. Each
batch of chemicals should have test certificate that all the chemicals should be bio-degradable
(preferably within 24 hrs), environment friendly and do not fall under banned category.
i) Total quantity of chemicals, to be supplied by the Vendor, should be adequate for 365 days
operation of the plant in a year.
j) The offer should be realistic. Under quoting or offering lower doses of chemicals than
required except where ever minimum dosage is specified will call for rejection. During the
tenure of treatment, if corrosion rates are within permissible limits, vendor shall optimize the
use of chemicals in consultation with the unit personnel without compromising the water
quality and guaranteed parameters.
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k) Vendors are advised to visit plant site and submit proposal only after extensive plant survey,
ascertaining quality of makeup, circulating water, blow down, equipment metallurgy etc.
Vendor shall assess the requirement of usage of each chemical and will quote appropriate
dosages to meet the guarantees. Vendor is free to quote Chemicals over and above the
ones specified in these documents to meet the guarantees. No complaints of the vendor
will be entertained after issue of work order.
l) Vendor shall provide analytical method of analysis along with active content and their value
in bulk chemicals, details of instruments on returnable basis /reagents required for analysis of
various Chemical’s active content. Instruments (on returnable basis) /reagents required for
analysis of chemicals as active ingredients in formation and in circulating water shall be
provided by the vendor free of cost. If these methods are not submitted by the vendor,
price bid will not be opened. NFL has the right to check the analysis of the lot of the bulk
chemicals received on random basis (minimum four times in a year), in its own lab or from a
reputed lab outside. In case active ingredient is lower with respect to minimum of the value
specified by party, deduction from the delivered cost on prorata basis, shall be done for said
total chemical supplied in that lot. In addition to above, cost of testing if done from lab other
than NFL’s own laboratory, shall be borne by vendor for such case. However in case the test
results are within specified limits, cost of testing shall be borne by NFL. No credit shall be
given to vendor for supplying chemical having higher than quoted active ingredient. Vendor
shall specify names of at least three such labs, where analysis of active ingredient of its
chemicals can be obtained by NFL.
Corrosion Inhibitor % of total inorganic phosphate as PO4
% of Zinc as Zn
Dispersant % of Organo-phosphonate
Sequestration value mg/ml (minimum)
Bio dispersant % Active ingredient & physical property
NaClO2/NaBr % active content
Non- Oxidizing Biocide as described in clause 3.2.3 (iv)
m) Vendor shall carry out daily water analysis to monitor the necessary treatment parameters.
NFL has the right to check the analysis. Lab facilities shall be provided to the vendor for the
above analysis. However, for analysis of chlorine dioxide and Zinc, spectrophotometer shall
be provided by the vendor. All reagents for testing/analysis are in the scope of vendor.
n) Corrosion coupon will be assessed jointly by NFL and vendor.
o) Microbiological analysis will be carried out by NFL in the presence of Vendors'
representative.
3.2 CW Treatment Scheme
3.2.1 pH Control
Treatment program should be designed in such a way that the pH of circulating water in
return header is kept within 6.8-8.0. pH in circulating water shall not be allowed to go below
6.5 at any time. Vendor shall maintain the same with his treatment. During exigencies when
pH goes higher than the specified value, pH can be maintained by dosing concentrated
Sulphuric acid. When pH goes below the specified value vendor shall be permitted to control
pH by dosing Soda Ash, if so required. pH reduction can take place under following
conditions:
i) Microbiological activities.
ii) Ingress of acidic gases/ leakage in heat exchangers
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a) pH reduction due to microbiological activity should be avoided. In case of such occurrence,
reasons for such an occurrence shall be established to the satisfaction of NFL and corrective
action must be taken immediately for which vendor shall use biocide. If pH reduction is due
to other reasons, the contractor may be allowed by NFL to use Soda Ash. Bidder shall
intimate the quantities of Soda Ash to be consumed for each cooling tower separately in
techno-commercial bid. Price of Soda Ash shall be indicated in the price bid. The maximum
quantity of soda ash permitted per year for all towers taken together will be limited to 24 MT/
year.
b) In case of pH reduction due to ingress of acidic gases/ exchanger leakage, soda ash dosing
shall be permitted for pH correction, which will be in NFL’s account. Such dosing shall be
decided by mutual consent in writing prior to start of dosing. Soda Ash required for dosing
under all conditions shall be arranged by bidder. Soda Ash supplied shall be of 95-99%
content of Na2CO3 (by wt).
3.2.2 Corrosion Inhibitor and Anti-Scaling Dispersant:
The treatment programme should be capable of maintaining corrosion rate less than 3.0
mpy on MS un- passivated sand blasted corrosion coupons (C 1010/UNSV-1010)
manufactured as per IS 12492-1988, to be supplied by NFL and shall be installed in return
header every month in each cooling tower. Corrosion racks and necessary fittings to be
provided by vendor.
One additional rack shall be available as common spare (standby) for all towers. The
corrosion coupons shall be sealed by NFL and party’s representative will be associated with
such sealing. All keys shall be kept with plant authorities.
Party should give percent (%) composition of total inorganic phosphate & Zinc in their corrosion
inhibitor. Normal of 6-9 ppm of total inorganic phosphate and 1 ppm of Zinc is preferred to be
maintained by regular chemical dosing at all times in circulation water. Bid evaluation shall be
done based upon the quoted quantity and active content in the formulation by the vendor.
a) The scale inhibitor-cum-dispersant shall take care of chances of scaling due to operation at
high pH and high temperature. Procedure for analysis of dispersant in circulating cooling
water is essential along with the technical bid. To take care of the adverse effects of higher
pH during monsoon season, doses of dispersant are to be maintained on sufficiently higher
side to avoid scale formation in critical exchangers where cooling water is on shell side with
low velocity. The dispersant offered should be proven and supporting documents for the
same to be provided.
b) In case of some critical exchangers, a need may arise for localized (satellite) dosing of
dispersant. The Vendor should be ready with necessary arrangements for the same. Doses of
dispersant should be selected accordingly.
c) Dispersant Test: Recommended dispersant should give min. 95 % of Ca3(PO4)2 inhibition
test at 50 % of the recommended dose level under test condition which are pH: 8, Ortho-
PO4: 8 ppm, temperature 70 0C and Ca hardness 500 ppm as CaCO3 in presence of total iron
of 1.0 mg/ lit in cooling water system. NFL reserves the right to test the dispersant.
3.2.3 Micro Biological Control:
i) Chlorination shall be done continuously to maintain free residual chlorine level of 0.2
ppm in return header of each cooling tower.
ii) Any excess of chlorine should be avoided due to its harmful effects.
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iii) Chlorine dioxide or Sodium Bromide shall be dozed for which vendor shall provide a
chlorine dioxide generator for in-situ generation.
iv) At least three non-oxidising biocides out of the following suggestive biocides are to
be recommended by the vendor so as to achieve the guaranteed figure as per clause
No. 3.7. Minimum active contents of biocide and ppm dose based on hold up volume
for effective bio control shall be as follows:
S. No Biocide type Minimum (%)
Active content
Minimum (ppm) dose
based on Hold up
1 Quaternary Ammonium
compounds (QUAT)
40 25
2 Carbamate based 45 30
3 Isothiozoline based 1.4 30
4 Methylene bis thiocynate
(MBT) based
9 25
5 Diclorophene based 40 30
Minimum dosing frequency of non-oxidising biocide will be once in two weeks per
tower and a minimum of 26 doses per year per tower, preferably, with sequential
dosing. Changes in the biocides, if any, will be reviewed after actual application and
monitoring of the system.
v) Party shall submit procedure for analysing active ingredients of all the offered
biocides. If offered biocide active contents and/or dose are less than the above, NFL
reserves the right to reject the bid technically or modify the dose to arrive at aforesaid
minimum requirement and load the additional quantity. If offered concentration/dose
is more than specified above, then offered quantity shall be considered for evaluation.
Vendors can also quote biocides other than listed above. However vendor shall
submit adequate proof that the offered non-oxidising biocide with indicated
active ingredient and dosage has been used successfully for at least 2 years in
other ammonia/urea cooling towers, backed up by user certificate. Effectiveness of biocide at quoted levels can be independently verified by NFL
through certified laboratories. If dosage level is found inadequate, then quantity can
be enhanced by NFL, cost of which will be borne by vendor. Result of test will be
binding on the party.
vi) A dedicated bio-dispersant shall be dosed on continuous basis to keep the system free
from bio-film formation. Minimum dosage of 3.0 ppm of bio dispersant in
circulating water is to be maintained.
3.2.4 Operating Parameters:
In addition to details specified above, the vendor should also consider the following, while
designing the treatment.
a) Holding time index / large system volume and limitation in blow down rate. COC is
preferred to be in the range of 6-8. However, vendor shall assess the requirement based
upon actual operating data available with Bathinda Unit.
b) Water quality as specified at 2.6.1.
c) High temperatures in the CW heat exchangers (both on process and CW sides).
d) Nitrifying bacteria should be maintained, preferably < 25 counts/ml on a monthly basis.
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Vendor will provide control limits for following circulating water parameters to be
measured on daily basis:
Circulating Water Parameter Unit Normal Maximum*
pH
Free residual chlorine ppm as Cl2
Chlorine Dioxide (ClO2)
Oxygen reduction potential (ORP)
Turbidity
Total hardness as CaCO3
Calcium hardness as CaCO3
Magnesium hardness as CaCO3
Zinc ppm
Ortho phosphate as PO4 (ppm)
Total Phosphate ppm PO4
Scale dispersant
Silica as SiO2
Bio dispersant
Chloride as Cl
Cycle of Concentration
M alkalinity as CaCO3
Iron content
SRB
TBC/TPC
Maximum value shall be applicable based on the quality of makeup water as mutually agreed
before starting the treatment. It is desired that normal control limits should not be crossed. In
case of exceeding the normal limits, necessary information shall be conveyed to Production
In charge and corrective action taken immediately.
3.3 Contingency Treatment: 3.3.1 The vendor shall have a contingency treatment programme to take care of the effect of
various contaminants.
The limits of contaminants in CW circulating water shall be as follows:
Contaminants Ammonia CT
PPM (Max)
Urea CT
PPM (Max)
CPP CT
PPM (Max)
Ammonia 60 250 20
Urea 10 10 10
Oil 10 10 10
3.3.2 Contingency shall be decided at the time of its occurrence by mutual consent, in writing, by
NFL. Same shall be approved by Unit In-charge prior to the start of contingency treatment. A
contingency shall be declared, if disturbed condition persists for 48 hrs (forty eight hours)
for ammonia & Urea and immediately on detection of oil. The bidder should indicate the
details of chemicals to be used along with quantity for meeting each contingency for each
tower separately. This treatment shall remain effective for 72 hours.
Loading of quotations against contingencies shall be made based on the number of
contingencies as stipulated below:
Ammonia CT Urea CT CPP CT
Oil 1 1 1
Ammonia 1 3 0
Urea 0 0 0
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In case, the contingency like leakage of cooling water from underground header etc, is not
controlled within a reasonable time and NFL decides to continue with it in order to avoid
plant interruption, then the modalities of using additional chemicals shall be discussed and
agreed mutually. The continuation of contingency as well as additional expenditure on this
account shall require prior approval of the Unit In-charge.
3.4 Alternative chemicals for water treatment The contractor may sometimes find it necessary to change one or two chemicals during the
treatment based on his experience regarding efficacy of the chemical in use. Since the
contractor shall be in a better position to know regarding nature of makeup water, circulating
water and effectiveness of the treatment, after carrying out the treatment for some time,
allowing use of alternative chemicals is considered in the interest of achieving better results.
For this purpose vendor shall specify all such alternative chemicals along with their unit rates
in the quotation itself. Main chemical shall be taken for the purpose of bid evaluation and
calculating guaranteed cost. Any chemical not in bidding list, if needed can be agreed after
mutual discussion and prior approval of Unit In-charge. However, the overall guaranteed cost
shall remain the same.
3.5 Mobilization Period & stabilization period: Mobilization period for starting the treatment
shall be one-month maximum from the award of contract or as mutually agreed.
However, contract period for the purpose of calculation of the number of days shall be with
effect from the actual date of start of treatment programme. Stabilization period shall be
one month (max.) from the date of start-up of the Cooling Water Treatment or as
mutually agreed. The trial period of six months, where ever applicable, shall include one
month of stabilization period. No penalty shall be levied during stabilization period. If
existing vendor continues for the next contract, there shall be no stabilization period.
3.6 Monitoring
3.6.1 Monitoring Tools: Vendor should be equipped with gadgets for monitoring the health of the
cooling water system, including simulation capabilities for trouble-shooting. Gadgets for
studying fouling factor, heat flux etc. on line shall be required. Vendors should clearly
mention the details of the monitoring instruments which will be supplied free of cost with the
package for use at site on returnable basis.
Following online / other monitoring instruments are to be provided for each tower from the
Vendors:
a) Bio-fouling monitors (with differential pressure gauge)
b) Online Deposit monitors.
c) Corrosion racks with necessary fittings and screws compatible with corrosion coupon.
d) Analytical kit for field testing (with reagents replenishment).
e) Corrator facility for instantaneous corrosion rate (Minimum twice in month during
normal operation).
f) ORP monitor
g) Dosing system including metering pumps and replacement of spares as and when
required. Vendor shall keep necessary spare dosing and monitoring system and spares
parts at site so that chemical dosing system and monitoring system can be kept in service
uninterrupted. If the vendor fails to maintain the system in healthy condition the same
will be attended by NFL at the cost and risk of the vendor. To ensure precise addition of
chemicals on continuous basis, the dosing system shall comprise all the parts/pumps
/equipments/pipelines/valves to ensure the dosing of different chemicals from dosing
tank right up to the basin and any other equipment required to achieve the dosing on
continuous and uniform basis.
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h) PC based Software and hardware for trend check.
i) Any other instrument for simulation and diagnostic study
3.6.2 Vendor should have access to a full-fledged R & D facility of his own. The party should have
properly trained team for trouble-shooting of the problems associated with this cooling water
treatment.
3.6.3 Monitoring Services:
Vendor should carry out the following:
a) Continuous monitoring and supervision by his specialist(s) during pre-cleaning &
passivation initially and also on day-to-day basis, during normal operation.
b) Reporting to plant personnel & submission of daily analysis report to Plant In-charge by
4.00 pm every day. Involve NFL personnel in the operation and control of the treatment.
c) Submission of monthly report on water quality and monthly consumption of chemicals.
d) Reports with detailed analysis and corrective actions for excess consumption of normal
and / or contingency chemicals, if any.
e) Trouble shooting as and when required through vendor's resident expert.
f) Training of NFL personnel periodically w.r.t cooling water treatment developments.
3.6.4 Vendor should depute a supervisor cum Chemist at their cost for trouble-shooting and
analysis to take care of the on-going cooling water treatment. The qualification & experience
in fertilizers industry cooling water treatment of the supervisors should be submitted along
with the technical bid.
3.6.5 Dosing of all chemicals (regular as well as contingency) shall be the total responsibility of
the Vendor. In case the plant is being operated under disturbed conditions of leakage etc
leading to deviation in cooling water parameters, pH of cooling water will be checked every
2 hours for 2-3 days to find optimum dosage of chemicals to take care of the situation.
3.7 Essentials/Performance Guarantees
Vendor will furnish the following guarantees for the performance of their C.W. treatment
programme. Written procedure shall be submitted for analysis and ascertaining the
guarantees, which shall be approved by NFL.
3.7.1 Corrosion Rate:
The corrosion rate as measured on sand blasted MS, un-passivated test coupons (C
1010/UNSV-1010) as per IS 12492-1988 procedure separately for each tower should not
exceed 3mpy ( measured in return header).
a) Analysis shall be reported as a rational number up to one decimal place after
rounding off as per procedure laid down in IS: 2-1960.
b) The test coupon shall be removed normally after duration of 30 days. However, in
case of any exigencies, the time limit may vary by plus minus 5 days after approval
of Unit in-charge.
c) In case of completion of 6 months of trial period, if the test coupon has not completed
30 days, another 15 days (max.) shall be allowed to ascertain the performance for 30
days, which shall be allowed after approval of Unit head.
d) In case cooling water circulation is stopped for more than 8 hours, the test coupons
shall be rejected.
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3.7.2 Micro Biological Count: Bidder shall guarantee cooling water system free of undesirable
biological growth (to be measured every week) throughout the period of operation. Total
bacterial count (TBC) should not exceed 1.0 lac/ml on fortnightly basis Sulphate Reducing
Bacteria (SRB) should not exceed 100/100 ml on fortnightly basis.
3.7.3 Iron in circulating water < 1.0 ppm on fortnightly average of iron analyzed on daily basis. 3.7.4 There should not be any tube leakage or fouling of heat exchangers due to inadequacy in the
C.W. treatment, which may result in stoppage of plant. Inspections during planned shutdowns
should reveal that heat exchangers and cooling water system is in good condition without
serious corrosion, pitting, scaling or fouling.
3.8 Penalties and termination
In case, the conditions, mentioned under the ‘Guarantees’, are not met, the following
penalties shall be levied on a yearly basis.
3.8.1 Corrosion rate: a) If the guaranteed corrosion rate for any of the Cooling Towers, exceeds 3 mpy Rs 25000
per tower, shall be deducted for each of such failure.
b) In addition to above deduction, if the failure occurs consecutively in following month for
same tower, 20% of the SD cum PBG on prorata basis (Total SD cum PBG amount X
number of towers where failure occurred / total number of towers being treated) will be
forfeited and vendor shall be given 30 days from occurrence, to rectify the same.
c) If failure occurs third time consecutively in same tower balance amount of SD cum
PBG, as defined in clause 3.8.7, shall be forfeited and contract is liable to be
terminated.
d) Further, if corrosion rate exceeds 3 mpy on any four occasions in same tower during term
of contract for one year, balance amount of entire SD cum PBG amount shall be forfeited
as per clause 3.8.7 and contract is liable to be terminated.
3.8.2 If any of the three parameters, (TBC, SRB and Fe), individually exceed the limits in any one
tower mentioned above during the term of the contract (excluding stabilization period), vendor
shall be allowed to modify treatment at his cost. However, if any one or more of the parameters
remain out in a consecutive/s reading anytime during the term of contract, Rs 10000 per tower per
parameter shall be deducted.
3.8.3 NFL shall have the right to terminate the contract, in case of any eventual unsatisfactory
performance including heavy fouling of heat exchangers due to which plant has to be
stopped, notwithstanding various provisions of the contract.
3.8.4 In case due to unsatisfactory performance of the contract, termination clause becomes operative, a
termination notice of 15 days (minimum) to 3 months shall be given to the vendor. The contract
shall be terminated after expiry of the notice period. During the notice period, all terms and
conditions as applicable in the contract shall apply. However, No penalties w.r.t. guaranteed
parameters of corrosion rate, TBC, SRB, Fe shall be applicable.
3.8.5 The total liability of the vendor during one year term of contract on account of failure to meet
guarantees of corrosion rate, SRB, TBC, Fe under 3.8.1 and 3.8.2 will be limited to SD cum PBG
amount, as per clause 3.8.7, plus penalty amount deducted under clause 3.8.1 (a).
3.8.6 The SD cum PBG amount will be 10% of total guaranteed order value worked out as per
Section 4.3.
14
3.8.7 In case termination clause becomes operative, forfeiture of SD cum PBG shall be as follows,
in addition to liabilities under clause 3.8.1(a):
a) If termination clause is operated within first six months of the start of treatment, total amount
of SD cum PBG submitted (i.e. for all towers on annual basis) shall be forfeited.
b) If termination clause is operated between seventh to ninth months of the start of the
treatment, total amount equivalent to 75% of the SD cum PBG submitted (i.e. for all towers
on annual basis) shall be forfeited.
c) If termination clause is operated between the tenth to twelfth month from the start of the
treatment, total amount equivalent to 50% of the SD cum PBG amount (i.e. for all towers on
annual basis) shall be forfeited.
It is further clarified that in case any deduction has been made earlier as per clause 3.8.2 or
from SD cum PBG according to 3.8.1(b), same shall be refunded/ adjusted against the above
forfeiture amount of SD cum PBG amount.
3.8.8 In case a regular contract is terminated on unsatisfactory performance, the vendor shall be put
on holiday for one year for Bathinda Unit.
SECTION – C
4.0 Instruction to Bidders for bidding documents
4.1 Technical Quote a) Bidder shall quote separately for Ammonia, Urea and CPP (wherever applicable) Cooling
Water treatment in respect of control parameters of circulating water, chemical dosing rate,
chemical consumption, Unit rates etc.
b) Bidder shall indicate the maximum consumption of each regular chemical to be supplied by
him, for each cooling tower per month. Maximum payable/guaranteed contract amount shall
be calculated for all towers taken together, on yearly consumption based on 365 days of
regular operation of cooling towers.
c) Bidder shall also mention tower wise maximum consumption of sulphuric acid and chlorine
to be supplied by NFL as free issue materials.
d) Any extra chemicals, required for change over from existing treatment to new treatment shall
be mentioned separately.
e) After annual shutdown and draining of Cooling Tower, the requirement of Pre-cleaning/ bio-
cleaning and passivation chemicals as well as one extra charge required due to refilling of
cooling tower, should be indicated separately.
f) Contingency chemicals and their quantities for contingency, as foreseen by Bidder (Ref
Clause 3.3) for each cooling tower, shall be indicated separately. Same shall be included in
evaluation of bid.
g) In case of any additional shutdown during the year which has resulted in draining of the
water from the cooling tower (s), the additional initial fill, pre-cleaning/ bio-cleaning and
passivation chemicals including biocide and bio dispersant whichever required, shall be
allowed after approval of competent authority.
h) Bidder should specify the time period for stabilization before start of normal treatment
programme. Maximum stabilization period shall be 30 days from start up of cooling water
treatment. In case of any interruption in this duration, due to shut down resulting in draining
of cooling towers, stabilization period shall be extended suitably after mutual discussions
with NFL. However, contract period shall remain the same and payment shall be released for
chemical consumption on actual but limited to overall cost of all the towers taken together on
yearly basis.
15
i) Chemical consumption shall be calculated on the basis of C.O.C., blow down quantity as
mentioned in ‘details of existing cooling water system’ in Section-A. Bidder shall furnish
calculations for the same.
j) Contract shall initially be for one-year duration, which on successful execution may be
extended for another year. Vendor shall, however, quote for a period of two years during
which the quoted rates shall remain firm.
4.2 Bid Evaluation:
Following shall be considered for the purpose of bid evaluation only:
i) For the purpose of evaluation, cost of all towers shall be clubbed together on an annual basis.
ii) Cost of chemicals for regular treatment based on bidders quotation in terms of quantity
and unit rates shall be considered for 365 days of operation in a year.
iii) Cost of chemicals required for change over from existing treatment to new treatment.
iv) Cost of Pre-cleaning/ bio- cleaning and passivation chemicals as well as one charge required
due to refilling of cooling tower, after annual shutdown and draining of Cooling Tower.
v) Cost of Contingency chemicals based on quantities indicated by bidder for each contingency
and for number of contingencies as listed at 3.3 for each cooling tower.
vi) Equivalent cost of sulphuric acid and chlorine to be supplied by NFL, based on maximum
quantities indicated by bidder for 365 days.
vii) Landed cost of Soda Ash quoted in price bid format subject to maximum of 24 MT /year as
per clause 3.2.1(b).
It is however, clarified that guaranteed overall annual cost shall be calculated as detailed at 4.3
below:
4.3 Guaranteed overall annual cost: a) Vendor shall guarantee the overall annual cost of treatment chemicals, which shall be worked
out as follows. However payment shall be released based on actual consumption of chemicals
limited to overall guaranteed cost.
b) Guaranteed overall annual cost shall be worked out as follows:
i) The cost shall be clubbed for all the towers on yearly basis.
ii) Landed Cost of chemicals for regular treatment based on bidders quotation in terms of
quantity and unit rates shall be considered for 365 days of operation in a year. In case
there is a variation in actual operating days, adjustment shall be made on pro-rata basis
for either side. Any excess consumption above the adjusted quoted value shall be, to the
vendor’s account.
iii) The quantity of sulphuric acid, which is supplied to the vendor as free issue materials by
NFL, shall be clubbed for all the towers. Any additional quantity consumed over and
above the quoted quantity shall be to the bidders account.
iv) The quantity of chlorine, which is supplied to the vendors as free issue materials by NFL,
shall be clubbed for all the towers. Any additional quantity consumed over and above the
quoted quantity shall be to the bidders account.
v) Quantity of sulphuric acid and chlorine as quoted by the bidders shall be considered
separately. These shall not be adjusted against each other nor shall these be included in
the guaranteed overall annual cost.
vi) Any extra chemicals, required for change over from existing treatment to new treatment
shall be mentioned separately. These shall not be included in guaranteed annual cost.
Payment against these chemicals shall be made on the basis of actual consumption,
limited to quoted value, over and above the Guaranteed overall annual cost.
vii) Pre-cleaning/ bio- cleaning and passivation chemicals as well as one charge for refilling
of cooling tower after annual shutdown, should be indicated separately and shall be paid
additionally, on actual consumptions. These shall not be included in guaranteed annual
cost.
16
viii) The contingency chemicals as quoted by the bidders shall not be included in
guaranteed overall annual cost. Payment against these chemicals shall be made on the
basis of actual consumption, limited to quoted value, over and above the Guaranteed
overall annual cost.
ix) Payment against all chemicals shall be made on actuals but limited to total quoted
quantity.
x) Landed cost of soda ash quoted in price bid format subject to maximum of 24 MT/ per
year as per clause 3.2.1 (b).
c) Any excess consumption of sulphuric acid or chlorine shall be charged at current price.
Current price shall mean landed price for the period after vendor has consumed the total
quantity of these chemicals as specified in contract. No departmental charges shall be
charged for over consumption.
d) Any chemical, other than sulphuric acid and chlorine shall not be supplied by NFL. The
chemicals like Soda Ash etc. (if required) shall be in the scope of the Contractor.
4.4 Vendor’s Scope
Vendor’s scope of work, supply and services shall be as described below:
i) Design of suitable cooling water treatment programme to meet the system requirements and
technical specifications.
ii) Supply of chemicals for initial change over, normal operations, contingencies and extra
charge for refilling of cooling tower after annual shutdown.
iii) To provide and maintain dosing system inclusive of metering pumps for chemical dozing,
including the pumps for chemicals for pH control; special instruments for monitoring the
treatment programme; Corrosion rack, bio-fouling monitors and scale monitors etc. free of
cost to NFL, on returnable basis.
iv) Supervision by Vendor’s specialist(s) during initial commissioning, change over and
stabilization of treatment package followed by round the clock regular supervision during
normal operations. Vendor specialist shall be well qualified and experienced. Vendor shall
obtain approval of bio data of his specialists from NFL prior to his appointment at site.
v) Training of NFL personnel in the operation and monitoring of cooling water treatment.
vi) Chlorine dioxide generator and Spectrophotometer for analyzing Chlorine dioxide along with
reagent to be provided by vendor, which shall be taken back after completion of contract.
4.5 Owners Scope NFL’s scope of supply and responsibilities shall include the following: -
i) Sulphuric Acid (98% concentration) shall be made available in the storage tanks near the
Cooling Tower.
ii) Chlorine in One Tonne cylinders shall be placed at the specified locations.
iii) In general, NFL shall not supply any additional chemical other than chlorine and
sulphuric acid. However, in case NFL agrees on emergency basis as a special case, same
shall be supplied by NFL on chargeable basis with additional 25% departmental charges.
iv) Power connections shall be provided to all the equipments/ instruments for dozing
operations and monitoring.
v) Laboratory assistance, to the extent available, shall be provided.
vi) NFL shall make available test coupons manufactured as per (C 1010/UNSV-1010) as
per IS 12492-1988 specifications.
vii) NFL shall operate the system under guidance of Vendor’s specialist.
viii) Accommodation to site engineers of vendor shall be furnished subject to the
availability and on chargeable basis at commercial rates.
ix) RAX telephone facility will be provided at the residence of the vendor in township for
better communication.
17
4.6 Trial order
i) If vendor has been pre-qualified for placement of order on trial basis then order shall be
placed on trial basis for a period of six months (Including stabilization period).
ii) In case of orders placed on trial basis, vendor shall submit SD cum PBG equivalent to 10% of
the full order value of the contract (one year period).
iii) No Penalties as per clause 3.8.2 will be applicable under the trial period. However penalty for
corrosion rate as per clause 3.8.1 (a) shall be applicable.
iv) In case of failure of trial order, payment shall be released to vendor for chemicals consumed.
However amount equivalent to 10% of the guaranteed order value for 6 months for the tower
(s) where failure occurred , on prorata basis (Total SD cum PBG amount * number of towers
where failure occurred / total number of towers being treated) shall be forfeited from the SD
cum PBG and order closed.
v) Performance Conditions for trial order
Cooling water treatment on trial basis will be considered unsatisfactory on the basis of
following:
a) If corrosion rate is more than 3.0 mpy consecutively in two months (other than
stabilization period) for same tower OR
b) If corrosion rate is more than 3 mpy on any three occasions, in same tower during the
trial period (excluding stabilization period).
vi) If a trial order fails at one Unit of NFL the vendor shall continue to be considered for the
other units for trial.
vii) Vendor can quote at two or more units in simultaneous bidding , In case the vendor is L-1 at
all locations, order shall be placed only for that Unit where price bid was opened earlier.
viii) In the event trial order is successful, all terms and conditions as applicable for regular
treatment shall become applicable from start of treatment i.e. six months of trial period plus
balance period of six months. The penalties with respect to SRB, TBC and Fe will be only in
the last six month (for a contract ordered on annual basis during first year) after successful
completion of trial period.
4.7 Contents of Offer
i) Bidder shall furnish details of the treatment programme including the following:
a) Descriptions of programme.
b) Chemicals used, giving name, code number and function i.e. passivating agent, anti- scaling,
dispersant, bio-dispersant, biocide and any other specific chemicals along with active matter,
concentration and percentage kill of biocides.
c) Dozing rates, monthly consumption as well as yearly consumption of chemicals for each
Cooling Tower. This shall include the quantity of sulphuric acid, chlorine as well as soda ash
(if required). These shall be supported by design calculations.
ii) The treatment program for each cooling tower should be separately indicated for (a) Pre-
cleaning and passivation, (b) Normal Treatment, (c) Contingency treatment for each
contingency tower wise.
iii) Vendor shall submit complete procedure and time required for the change-over of the new
treatment.
iv) Detailed description of the philosophy and working of the automatic feed monitoring and
dosing system (wherever applicable).
v) Source of supply of the chemicals, including quality control system.
vi) Details regarding similar experience in implementing cooling water treatment programs.
These shall include name, location and details of the plant, specification of treatment system,
period of operation, analysis / inspection report.
vii) Data sheets containing product specifications, special precautions for handling the chemicals,
disposal of empty containers, remedial measures to be taken in case of spillage and ingress
into human body etc. shall be furnished.
18
viii) The chemicals shall be supplied in good quality containers. Vendor shall take back all
the used containers.
ix) The chemicals that shall be left over after the contract is closed shall normally be taken back
by the vendor. However in case, it is desired by NFL, then full/part of the left over chemicals
shall be retained by NFL and the payment against the same shall be made separately.
4.8 Splitting of Contract All cooling towers in the Unit shall be clubbed in a single package for the purpose of bid
evaluation and subsequently placement of order.
4.9 Availability of chemicals without interruption Bidder shall guarantee supply of chemicals as per agreed schedule without interruption.
Normal schedule of supplies shall be every three months, so that the site inventory level does
not fall below 2 month’s requirement. Additional one-month’s chemicals are considered
during transit. However, during last month of the contract period, the spare inventory of
regular chemicals as mentioned above shall not fall below one month’s requirement. Further
the pre-cleaning, passivation and contingency chemicals leftover at the end of the contract
shall be taken back by the vendor and NFL shall recover the corresponding amount from the
vendor, if already paid for.
19
Annexure-I
N.F.L. BATHINDA UNIT
Normal Make up water analysis for 2015-16
Characteri
stics
Months
April
15
May
15
June
15
July
15
Aug
15
Sept
15
Oct
15
Nov
15
Dec
15
Jan
16
Feb
16
Mar
16
TH 104 105 94 93 100 90 93 97 106 109 107 104
Ca – H 74 75 64 63 70 60 63 67 76 79 77 74
Mg – H 30 30 30 30 30 30 30 30 30 30 30 30
Chloride 6 5 6 6 6 6 6 5 6 6 6 6
M-alk 58 62 58 52 55 51 52 51 58 58 58 58
Silica as
SiO2
2.12 2.24 2.04 2.02 2.60 2.38 2.42 2.32 2.30 2.24 2.16 1.80
Iron 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08
Sulphate
(SO4)
44.0 45.0 41.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 41.0 41.0
pH 7.8 7.8 7.8 7.8 7.8 7.8 7.8 7.8 7.8 7.8 7.8 7.8
All above parameters are in mg/l except pH
20
Annexure-II (a)
N.F.L. BATHINDA UNIT
AMMONIA PLANT EXCHANGERS’ DATA after Revamping
Exchanger Name/Code Cooling Water in Tube
side/Shell side
Material of
Construction of tubes Heat Duty
(MKcal/Hr.)
A-EA-603 Synthesis Water Cooler Shell side SS 8.20
AGB-601 Surface Condenser TS SS 22.2
AGB-601-E1 Shell side SS 3.485
AGB-601-E2 -do- SS 3.663
AGB-601-E3 -do- MS 2.358
AGB-601-E4-A/B TS SS --
AGC-601 Surface Condenser TS SS 7.35
AGC-601-E1-A/B Ammonia Condenser TS SS 10.1
AGC-601-E2 TS SS --
AGA-701 Surface Condenser TS SS 8.320
AGA-701-T E.C. TS SS --
AGA-701-E1-A/B TS SS 0.066
AGC-001-EA-1 (KPC) TS SS --
X-921 N2 Generation Unit TS SS ----
X-501 Ammonia Refrigeration Unit TS ---- ----
E-552 Ammonia OH Condenser TS SS 0.82
E-554 Lean Solution Cooler TS SS 0.37
E-702 Stripped Cond. Cooler TS SS 1.46
E-705 Blow Down Cooler TS SS 0.17
E-401 Turbine Condenser of TK-431 TS SS 6.97
Oil cooler for TK-431 TS ---- -----
E-431 Syn. Gas Booster after cooler TS SS 3.13
E-404 Turbine Condenser of TK-421 TS SS ----
E-425 A/B Oil cooler for TK-421 TS SS ----
E-421 1st inter stage cooler of TK-421 TS SS 1.40
E-422 2nd inter stage cooler of TK-421 TS SS 1.28
E-423 3rd inter stage cooler of TK-421 TS SS 1.58
E-424 4th inter stage cooler of TK-421 TS SS 1.17
HVAC TS SS -
E-312 Final Cooler TS SS 2.25
E-214 Start Up Cooler TS SS 1.71
X-911 Instrument Air Dryer TS SS
Sample & Bearing Cooler ----- ---- ----
E-303 Lean Soln. Cooler TS SS 7.85
E-306 CO2 Product Cooler TS SS 2.67
E-316 Flash Gas Cooler TS SS 0.08
21
Annexure-II (b)
N.F.L. BATHINDA UNIT
UREA PLANT HEAT EXCHANGER DATA SHEET
Sr. No.
Name of Exchanger Heat Duty Material of Construction CW Flow IN
MMKCal/hr Shell Tube
1 Condensate cooler U-EA-103 0.727 SA 516G x 60 SS-304 Tube
2. Turbine Surface Condenser U-EA-104
10.800 IS-2062 SS-305 Tube
3. High Pr. Absorber Cooler U-EA-401
- SA 516 GH 70 Tube
4 Low Pr. Absorber UEA-402 7.252 SA-249 GH 304
SA-213 TP304 Tube
5 Purge NH3 Condenser UEA-403 3.83 SA 516 Gr 60
SS-304 Tube
6 NH3 Condenser UEA-404 A-E 3.028 x 5 SA 516 Gr 61
SS-304 Tube
7 NH3 Recovery Absorber UEA-405 (1/4,2/4, 3/4, 4/4)
0.586 SA 516 Gr 62
SA-304 Tube
0.244
0.16
8 Off gas condenser UEA-406 2.088 SA-240 Gr. 304
SA-213 TP 304
Tube
9 Off gas Absorber Final cooler 0.0909 SA-240 Gr. 305
SA-213 TP 305
Tube
10 Cooler for UDA-402 UEA-408 1.011 SA-240 Gr. 306
SA-213 TP 306
Tube
11 UGB-101 E1 1.10 A-515 Gr. 60 SS-304 Shell
E2 1.86 A-515 Gr. 61 SS-304 Tube
E3 1.40 A-515 Gr. 62 SS-304 Tube
12 CO2 booster oil cooler - SA-106 Gr. B SS-304 Tube 13 CO2 booster turbine ejector
condenser UGB-101-E5 - IS-2026 A-249 TD 304 Tube
14 Inter cooler for GB-102 U-EA-107 1.800 SS-41 A-213 TP-304 Shell
15 UGB-102 LO Cooler 0.0227 STPG-38 A 53 Gr. A
SS-304 Tub
22
Annexure II (c)
N.F.L. BATHINDA UNIT
HEAT EXCHANGER DATA SHEET – CPP
Name of
Exchanger
Heat Duty Material of
Construction
CW Flow in
Surface Condenser
of TG -1 & 2
22 x 106 Joules/sec S.S. 304 TUBE